Carbonylation involving novel catalytic materials



United States Patent US. Cl. 260-604 2 Claims ABSTRACT OF THE DISCLOSURE A process for carbonylatng an olefinic C -C hydrocarbon involving the reaction of the hydrocarbon with CO in the presence of a solid, porous crystalline aluminosilicate catalyst at a temperature of about 200-400 F. at a pressure of at least about 1,000 p.s.i.g.

The present invention relates to carbonylation reactions and, more particularly, to carbonylation reactions involving the use of novel catalytic materials.

Zeolitic materials, both natural and synthetic, in naturally occurring and modified forms, have been demonstrated in the past to have catalytic capabilities for the conversion of organic materials. Such zeolitic materials are ordered crystalline aluminosilicates having a definite crystalline structure within which there are passages, pores or cavities of definite ranges of size. Since the dimensions of these pores are such as to accept for adsorption molecules of certain dimensions while rejecting those of larger dimensions, these materials have come to be known as molecular sieves and are utilized in a variety of ways to take advantage of these properties.

The present invention involves the use of such Zeolitic materials for the purpose of catalyzing carbonylation reactions. More specifically, it has been found that such zeolites form excellent materials for catalyzing the reaction betwen organic compounds having a reactive carbon-carbon double bond and carbon monoxide.

It is accordingly a primary object of the present invention to provide a novel process for the catalytic carbonylation of organic compounds having a reactive carbon-carbon double band and more particularly an olefinic hydrocarbon having 240 carbon atoms.

It is another principal object of the present invention to provide a novel process for the carbonylation of organic compounds having a reactive carbon-carbon double bond comprising the use of a solid, porous crystalline aluminosilicate catalyst or isomorphs thereof.

It is still a further important object of the present invention to provide a novel process for carbonylating olefins to produce unsaturated aldehydes by means of a solid, porous crystalline aluminosilicate catalyst or isomorphs thereof.

It is another important object of the present invention to provide a novel process for carbonylating unsaturated halides involving the use of a solid, porous crystalline aluminosilicate catalyst or isomorphs thereof.

It is a further important object of the present invention to provide a novel process for carbonylating an organic compound having a reactive carbon-carbon double bond 3,489,810 Patented Jan. 13, 1970 involving the use of a solid, porous crystalline aluminosilicate catalyst, perferred ones of which include acid crystalline aluminosilicates (desirably having a minimum activity of at least about 10 in the hexane cracking test), rare earth-exchanged crystalline aluminosilicates and crystalline aluminosilicates containing a metal which Will form a carbonyl complex.

These and other important objects and advantages of the present invention will become more apparent upon reference to the ensuing description and appended claims.

As previously indicated, the present invention involves the use of solid, porous crystalline aluminosilicates (or isomorphs thereof) to catalyze the carbonylation of certain organic compounds. Broadly speaking any organic compound having a reactive carbon-carbon double bond may be carbonylated by means of the process of the present invention. While the invention is thus broadly applicable, preferred starting materials include olefins and unsaturated halides and preferred materials within these groups are olefinic hydrocarbons with carbon chains of C C When olefins are carbonylated in accordance with the present invention, unsaturated aldehydes are produced. Olefin polymerization, a competing reaction, is inhibited by the carbon monoxide and/ or the product aldehyde.

Representative of olefins which may be utilized as starting materials are straight-chain terminal olefins (i.e., ethylene; propylene; l-butene; l-pentene; l-hexene; 1- heptene; l-octene; l-decene, l-tetradecene), straight-chain internal olefins (i.e., Z-pentene; Z-hexene; Z-heptene, 3- heptene, 2-octene), branched terminal olefins (i.e., 4- methyl-l-pentene; Z-methyl-l-pentene; 2,4,4-trimethyl-lpentene; 2,3,3-trimethyl-1-butene; camphene), branched internal olefins (i.e., 4-methyl-2-pentene; 2-methyl-2- pentene; 2,4,4-trimethyl-2-pentene; 2, 3-dimethyl-2-butene, 2,6-dimethyl-3-heptene) and cyclic olefins (i.e., cyclopentene; cyclohexene; cycloheptene; cyclooctene; 4-methyl-1- cyclohexene).

Also highly desirable as starting materials within the frame work of the present invention are unsaturated halides, such as allyl chloride and bromide.

While the reactions of the present invention may be carried out solely in the presence of carbon monoxide as the carbonylation medium, the reactions are promoted by the presence of hydrogen at the reaction site, although the hydrogen does not appear to be consumed in the reaction.

The aluminosilicates useable as catalysts in accordance with the present invention include a wide variety of positive ion-containing crystalline aluminosilicates, both natural and synthetic. These aluminosilicates can be de scribed as a rigid three-dimensional network of SiO., and A10 tetrahedra in which the tetrahedra are cross-linked by the sharing of oxygen atoms whereby the ratio of the total aluminum and silicon atoms to oxygen atoms is 1:2. The electrovalence of the tetrahedra containing aluminum is balanced by the inclusion in the crystal of a cation, for example, an alkali metal or an alkaline earth metal cation. This equilibrium can be expressed by formula wherein the ratio of A1 to the number of the various cations, such as Ca, Sr, Na K or Li is equal to unity. One cation may be exchanged either in entirety or partially by another cation utilizing ion exchange techniques as discussed herein-below. By means of such cation exchange, it is sometimes possible, or even'desirable, to vary the size of the pores in the given aluminosilicate by suitable selection of the particular cation. The spaces between the tetrahedraare occupied by molecules of water prior-to dehydration.

A description of zeolites of the type useable in the present invention is found in Patent 2,971,824, whose disclosure is hereby incorporated herein by reference. These aluminosilicates have well-defined intra-crystalline dimensions such that only reactant or product molecules of suitable size and shape may be transported in either direction between the exterior phase and the interior of the crystalline Zeolite.

In their hydrated form, the aluminosilicates may be represented by the formula:

wherein M is a cation which balances the electrovalence of the tetrahedra, n represents the valence of the cation, w the moles of SiO and y the moles of H 0, the removal of which produces the characteristic open network system. The cation may be any one or more of a number of positive ions as aforesaid, such ions being discussed in greater detail hereinafter. The parent zeolite is dehydrated to actuate it for use as a catalyst. Although the proportions of inorganic oxides in the silicates and their spatial arrangement may vary, effecting distinct properties in the aluminosilicates, the main characteristic of these materials is their ability to undergo dehydration Without substantially affecting the SiO, and A framework. In this respect, this characteristic is essential for obtaining catalyst compositions of high activity in accordance with the invention.

Representative materials include a synthetic faujasite, designated Zeolite X, which can be represented in terms of mole ratios of oxides as follows:

wherein M is a metal cation having a valence of not more than three, n represents the valence of M, and y is a value up to eight depending on the identity of M and degree of hydration of the crystal. The sodium form may be represented in terms of mole ratios of oxides as follows:

Another synthesized crystalline aluminosilicate, designated Zeolite A, can be represented in mole ratios of oxides as:

wherein M represents a metal cation, n is the valence of M, and y is any value up to about 6. As usually prepared, Zeolite A contains primarily sodium cations and is designated sodium Zeolite A.

Other suitable synthesized crystalline aluminosilicates are those designated Zeolite Y, L and D.

The formula for Zeolite Y (which is a synthetic faujasite) expressed in oxide mole ratios is:

wherein w is a value'ranging from} to 6 and y may be any'valu e up to about 9. E v I The composition of Zeolite L in oxide mole ratios may be represented as:

whereimM designates -a metal cation, n represents the valence of M,'and y is any value from 0 to 7.

The formula for Zeolite D, in 'terms of oxide mole ratios, may be represented as:

O.9iO.2[xNa O:(1x)K O]:

wherein at is a value of 0 to l, wis from 4.5 to about 4.9 and y, in the fully hydrated form, is about 7.

- 4 .Othersynthetic crystalline aluminosilicates which can beused include those designated as Zeolite R, S, T, Z, E, E, Q and-B. The formula for Zeolite R in terms of oxide mole ratios may be written as follows:

0.9 0.2Na O :AI O WSIO2 yH O (VIII) wherein w is from 2.45 to 3.65, and y, in the hydrated form, is about 7.

The formula for Zeolite S in terms may be written as:

wherein w is from 4.6 to 5.9 and y, in the hydrated form, is about 6 to 7.

The formula for Zeolite T in terms of oxide mole ratios may be written as:

I (K20 1A1203'.

6.9 :0.5SiO H O of oxide mole ratios wherein M is a metal cation, n is the valence of the cation, and y is a value of 0 to 4.

The formula for Zeolite F in terms of oxide mole ratios may be written as:

0.95i-O.15M O:Al O

2.05i0.3SiO :yH O (XIII) wherein M is a metal cation, 12 is the valence of the cation, and y is any value from O to about 3.

The formula for Zeolite Q, expressed in terms of oxide mole ratios, may be written as:

0.95i0.O5M2/ O:AI2O3I 2.2i0.05SiO :yH O (XIV) wherein M is a metal cation, n is the valence of the cation, and y is any value from 0 to 5.

The formula for Zeolite B may be Written in terms of oxide mole ratios as:

wherein M represents a metal cation, n is the valence of the cation, and y has an average value of 5.1 but may range from 0 to 6.

Other synthesized crystalline aluminosilicates include those designated as ZK-4 and ZK-S.

ZK-4 can be represented in terms of mole ratios of oxides as:

2.5 to 4.0SiO :yH O (XVI) wherein R is a member selected from the group consisting of methylammonium oxide, hydrogen oxide and mixtures thereof with one another, M is a metal cation, n is the valence of the cation, and y is any value from about 3.5 to about 5.5. As usually synthesized, Zeolite ZK-4 contains primarily sodium cations and can be represented by unit cell formula:

TABLE 1 Value of reflection in A.: 100 I/I 12.00 100 9.12 29 8.578 73 7.035 52 6.358 15 5.426 23 4.262 11 4.062 49 3.662 65 3.391 30 3.254 41 2.950 54 2.725 10 2.663 7 2.593 15 2.481 2 2.435 1 2.341 2 2.225 2 2.159 4 2.121 5 2.085 2 2.061 2 2.033 5 1.90 2 1.880 2 1.828 1 1.813 1 1.759 1 1.735 1 1.720 5 1.703 1 1.669 2 1.610 1 1.581 2 1.559 1 ZK-4 can be prepared by preparing an aqueous solution of oxides containing Na O, A1 0 SiO H 0 and tetramethyl-ammonium ion having a composition, in terms of oxide mole ratios, which falls within the following ranges: slog/A120 2.5 to 11 N340 0.5 to 2.5 2 -i-[( 3)4 ]2 W to 2 H O 2 t '0 Na2O+[(GH N]2O 0 maintaining the mixture at a temperature of about 100 C. to 120 C. until the crystals are formed, and separating the crystals from the mother liquor. The crystal material is thereafter washed until the wash effiuent has a pH essentially that of wash water and subsequently dried.

ZK-S is representative of another crystalline aluminosilicate which is prepared in the same manner as Zeolite ZK-4 except that N,N'-dimethyltriethylenediammonium hydroxide is used in place of tetramethylammonium hydroxide. ZK-S may be prepared from an aqueous sodium aluminosilicate mxiture having the following composition expressed in terms of oxide mole ratios as:

SiO /Al O .2.5 to 11 M 0.5 to 2.5

sioz 1 to 2 The N,N'-dimethyltriethylenediammonium hydroxide used in preparing ZK-S can be prepared by methylating 1,4-diazabicyclo-(2.2.2)-octane with methyl iodide or dimethyl sulfate, followed by conversion to the hydroxide by treatment with silver oxide or barium hydroxide. The reaction may be illustrated as follows:

(XVIII) (XIX) H2 CH2 In using the N,N'-dimethyltriethylenediammonium hydroxide compound in the preparation of ZK-S, the hydroxide may be employed per se, or further treated with a source of silica, such as silica gel, and thereafter reacted with aqueous sodium aluminate in a reaction mixture whose chemical composition corresponds to the above-noted oxide rnole ratios. Upon heating at temperatures of about 200 to 600 C., the methyl ammonium ion is converted to hydrogen ion.

Quite obviously, the above-listed molecular sieves are only representative of the synthetic crystalline aluminosilicate molecular sieve catalysts which may be used in accordance with the process of the present invention, the particular enumeration of such sieves not being intended to be exclusive.

At the present time, two commercially available mo lecular sieves are those of the A series and of the X" series. A synthetic Zeolite known as Molecular Sieve 4A is a crystalline sodium aluminosilicate having an effective pore diameter of about 4 Angstroms. In the hydrated form, this material is chemically characterized by the formula:

The synthetic Zeolite known as Molecular Sieve 5A is a crystalline alumino-silicate salt having an effective pore diameter of about 5 Angstroms and in which substantially all of the 12 ions of sodium in the immediately above formula are replaced by calcium, it being understood that calcium replaces sodium in the ratio of one calcium ion for two sodium ions. A crystalline sodium aluminosilicate is also available commercially under the name of Molecular Sieve 13X. The letter X is used to distinguish the inter-atomic structure of this Zeolite from that of the A crystal mentioned above. As initially prepared and before activation by dehydration, the 13X material contains water and has the unit cell formula The synthetic Zeolite known as Molecular Sieve 10X is a crystalline aluminosilicate salt in which a substantial proportion of the sodium ions of the 13X material have been replaced by calcium.

Among the naturally occurring crystalline aluminosilicates which can be employed for purposes of the invention, the preferred aluminosilicates are those which sorb at least 2 wt. percent normal butane at 1 atm. and 25 C., i.e., those having a'pore diameter greater than about 5.4

7 A. Examples of such aluminosilicates include faujasite, dachiardite and mordenite. With the latter aluminosilicates, it is essential that they be in proper ionic form, else the pore diameter becomes smaller than 5.4 A.

Other aluminosilicates which can be used are those resulting from caustic treatment of various clays.

Of the clay materials, montmorillonite and kaoline families are representative types which include the subbentonites, such as bentonite, and the kaolins commonly identified as Dixie, McNamee, Georgia and Florida clays in which the main mineral constituent is halloysite, kaolinite, dickite, nacrite or anauxite. Such clays may be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. In order to render the clays suitable for use, however, the clay material is treated with sodium hydroxide or potassium hydroxide, preferably in admixture with a source of silica, such as sand, silica gel or sodium silicate, and calcined at temperatures ranging from 230 F. to 1600 F. Following calcination, the fused material is crushed, dispersed in Water and digested in the resulting alkaline solution. During the digestion, materials with varying degrees of crystallinity are crystallized outof solution. The solid material is separated from the alkaline material and thereafter washed and dried. The treatment can be effected by reacting mixtures falling within the following weight ratios:

Na O/c1ay (dry basis) 1.0-6.6 to 1 SiO /clay (dry basis) 0.01-3.7 to 1 H O/Na O (mole ratio) 35-180 to 1 Molecular sieves are ordinarily prepared initially in the sodium form of the crystal. The sodium ions in such form may, as desired, be exchanged for other cations, as will be described in greater detail below. In general, the process of preparation involves heating, in aqueous solution, and appropriate mixture of oxides, or of materials whose chemical composition can be completely represented as a mixture of oxides Na O, A1 SiO and H 0 at a temperature of approximately 100 C. for periods of minutes to 90 hours or more. The product which crystallizes within this hot mixture is separated therefrom and water washed until the water in equilibrium with the zeolite has a pH in the range of 9 to 12. After activating by heating until dehydration is attained, the substance is ready for use.

For example, in the preparation of sodium zeolite A, suitable reagents for the source of silica include silica sol, silica gel, silicic acid or sodium silicate. Alumina can be supplied by utilizing activated alumina, gamma alumina, alpha alumina, aluminum trihydrate or sodium aluminate. Sodium hydroxide is suitably used as the source of the sodium ion and in addition contributes to the regulation of the pH. All reagents are preferably soluble in water. The reaction solution has a composition expressed as mixtures of oxides, within the following ranges: SiO /Al O of 0.5 to 2.5, Na O/SiO of 0.8 to 3.0 and H O/Na O of 35 to 200. A convenient and generally employed process of preparation involves preparing an aqueous solution of sodium aluminate and sodium hydroxide and then adding with stirring an aqueous solution of sodium silicate.

The reaction mixture is placed in a suitable vessel which is closed to the atmosphere in order to avoid losses of water and the reagents are then heated for an appropriate length of time. Adequate time must be used to allow for recrystallization of the first amorphous precipitate that forms. While satisfactory crystallization may be obtained at temperatures from 21 to 150 C.,.the pressure being atmospheric or less, corresponding to the equilibrium of the vapor pressure with the mixture at the reaction temperature, crystallization is ordinarily carried out at about 100 C. As soon as the zeolite crystals are completely formed they retain their structure and it is not essential to maintain the temperature of the reaction any longer in order to obtain a maximum yield of crystals.

After formation, the crystalline zeolite is separated from the mother liquor, usually by filtration. The crystalline mass is then washed, preferably with salt-free water, While on the filter, until the wash water, in equilibrium with the zeolite, reaches a pH of 9 to 12. The crystals are then dried at a temperature between 25 C. and C. Activation is attained upon dehydration, as for example at 350 C. and 1 mm. pressure or at 350 C. in a stream of dry air.

It is to be noted that the material first formed on mixing the reactants is an amorphous precipitate which is, generally speaking, not catalytically active in the process of the invention. It is only after transformation of the amorphous precipitate to crystalline form that the highly active catalyst described herein is obtained.

Molecular sieves of the other series may be prepared in a similar manner, the composition of the reaction mixture being varied to obtain the desired ratios of ingredients for the particular sieve in question.

The molecular sieve catalyst useable in the process of the present invention may be in the sodium form as aforesaid or may contain other cations, including other metallic cations and/or hydrogen. In preparing the nonsodium forms of the catalyst composition, the aluminosilicate can be contacted with a non-aqueousor aqueous fluid medium comprising a gas, polar solvent or water solution containing the desired positive ion. Where the aluminosilicate is to contain metal cations, the metal cations may be introduced by means of a salt soluble in the fluid medium. When the aluminosilicate is to contain hydrogen ions, such hydrogen ions may be introduced by means of a hydrogen ion-containing fluid medium or a fluid medium containing ammonium ions capable of conversion to hydrogen ions.

In those cases in which the aluminosilicate is to contain both metal cations and hydrogen ions, the aluminosilicate may be treated with a fluid medium containing both the metal salt and hydrogen ions or ammonium ions capable of conversion to hydrogen ions. Alternatively the aluminosilicate can be first contacted with a fluid medium containing a hydrogen ion or ammonium ion capable of conversion to a hydrogen ion and then with a fluid medium containing at least one metallic salt. Similarly, the aluminosilicate can be first contacted with a fluid medium containing at least one metallic salt and then with a fluid medium containing a hydrogen ion or an ion capable of conversion to a hydrogen ion or a mixture of both.

Water is the preferred medium for reasons of economy and ease of preparation in large scale operations involving continuous or batchwise treatment. Similarly, for this reason, organic solvents are less preferred but can be employed providing the solvent permits ionization of the acid, ammonium compound and metallic salt. Typical solvents include cyclic and acyclic ethers such as dioxane, tetrahydrofuran, ethyl ether, diethyl ether, diisopropyl ether, and the like; ketones such as acetone and methyl ethyl ketones; esters such as ethyl acetate, propyl acetate; alcohols such as ethanol, propanol, butanol, etc.; and miscellaneous solvents such as dimethylformamide, and the like.

The hydrogen ion, metal cation or ammonium ion may be present in the fluid medium in an amount varying within wide limits dependent upon the pH value of the fluid medium. Where the alminosilicate material has a molar ratio of silica to alumina greater than about 5.0, the fluid medium may contain a hydrogen ion, metal cation, ammonium ion, or a mixture thereof, equivalent to a pH value ranging from less than 1.0 up to a pH value of about 10.0. Within these limits, pH values for fluid media containing a metallic cation and/or an ammonium ion range from 4.0 to 10.0, and are preferably between a pH value of 4.5 to 8.5. For fluid media containing a hydrogen ion alone or with a metallic cation, the pH values range from less than 1.0 up to about 7.0 and are preferably within the range of less than 3.0 up to 6.0. Where the molar ratio of the aluminosilicate is greater than about 3.0 and less than about 5.0, the pH value for the fluid media containing a hydrogen ion or a metal cation ranges from 3.8 to 8.5. Where ammonium ions are employed, either alone or in combination with metallic cations, the pH value ranges from 4.5 to 9.5 and is preferably within the limit of 4.5 to 8.5. When the aluminosilicate material has a molar ratio of silica to alumina less than about 3.0, the preferred medium is a fluid medium containing an ammonium ion instead of a hydrogen ion. Thus, depending upon the silica to alumina ratio, the pH value varies within rather wide limits.

In carrying out the treatment with fluid medium, the procedure employed comprises contacting the aluminosilicate with the desired fluid medium or media until such time as metallic cations originally present in the aluminosilicate are removed to the desired extent. Repeated use of fresh solutions of the entering ion is of value to secure more complete exchange. Effective treatment with the fluid medium to obtain a modified aluminosilicate having high catalytic activity will vary, of course, with the duration of the treatment and temperature at which it is carried out. Elevated temperatures tend to hasten the speed of treatment whereas the duration thereof varies inversely with the concentration of the ions in the fluid medium. In general, the temperatures employed range from below ambient room temperature of 24 C. up to temperatures below the decomposition temperature of the aluminosilicate. Following the fluid treatment, the treated aluminosilicate is washed with water, preferably distilled water, until the effluent wash water has a pH value of wash water, i.e., between about and 8. The aluminosilicate material is thereafter analyzed for metallic ion content by methods well known in the art. Analysis also involves analyzing the effluent wash for anions obtained in the wash as a result of the treatment, as well as determination of and correction for anions that pass into the effluent wash from soluble substances or decomposition products of insoluble substances which are otherwise present in the aluminosilicate as impurities. The aluminosilicate is then dried and dehydrated.

The actual procedure employed for carrying out the fluid treatment of the aluminosilicate may be accomplished in a batchwise or continuous method under atmospheric, subatmospheric or superatmospheric pressure. A solution of the ions of positive valence in the form of a molten material, vapor, aqueous or non-aqueous solution, may be passed slowly through a fixed bed of the aluminosilicate. If desired, hydrothermal treatment or a corresponding non-aqueous treatment with polar solvents may be effected by introducing the aluminosilicate and fluid medium into a closed vessel maintained under autogenous pressure. Similarly, treatments involving fusion or vapor phase contact may be employed providing the melting point or vaporization temperature of the acid or ammonium compound is below the decomposition temperature of the aluminosilicate.

A wide variety of acidic compounds can be employed with facility as a source of hydrogen ions and include both inorganic and organic acids.

Representative inorganic acids which can be employed include acids such as hydrochloric acid, hypochlorous acid, chloroplatinic acid, sulfuric acid, sulfurous acid, hydrosulfuric acid, peroxydisulfonic acid (H S 'O peroxymonosulfuric acid (H SO dithionic acid (H S O sulfamic acid (H NHS H), amidodisulfonic acid (NH(SO H) chlorosulfuric acid, thiocyanic acid hyposulfurous acid (H S O pyrosulfuric acid (H S O thiosulfuric acid (H S O nitrosulfonic acid (HSO .NO), hydroxylamine disulfonic acid s 2NOH] 10 nitric acid, nitrous acid, hyponitrous acid, carbonic acid and the like.

Typical organic acids which find utility in the practice of the invention include the monocarboxylic, dicarboxylic and polycarboxylic acids which can be aliphatic, aromatic or cycloaliphatic in nature.

Representative aliphatic monocarboxylic, dicarboxylic and polycanboxylic acids include the saturated and unsaturated, substituted and unsubstituted acids such as formic acid, acetic acid, chloroacetic acid, dichloroacetic acid, trichloroacetic acid, bromoacetic acid, propionic acid, 2-bromopropionic acid, 3-bromopropionic acid, lactic acid, n-butyric acid, isobutyric acid, crotonic acid, n-valeric acid, isovaleric acid, n-caproic acid, oenanthic acid, pelargonic acid, capric acid, undecyclic acid, lauric acid, myristic acid, palmitic acid, stearic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, alkylsuccinic acid, alkenylsuccinic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid, mesaconic acid, glutonic acid, muconic acid, ethylidene malonic acid, isopropylidene malonic acid, allyl malonic acid.

Representative aromatic and cycloaliphatic monocarboxylic, dicarboxylic and polycarboxylic acids include 1, 2-cyclohexanedicarboxylic acid 1,4 cyclohexanedicarlboxylic acid, 2-carboxy-2-methylcyclohexaneacetic acid, phthalic acid, isophthalic acid, terephthalic acid, 1,8- naphthalenedicarboxylic acid, 1,2 -napthalenedicarboxylic acid, tetrahydrophthalic acid, 3-carboxy-cinnamic acid, hydrocinnamic acid, pyrogallic acid, benzoic acid, ortho, meta and para-methyl, hydroxy, chloro, bromo and nitro-substituted benzoic acids, phenylacetic acid, mandelic acid, benzylic acid, hippuric acid, benzenesulfonic acid, toluenesulfonic acid, methanesulfonic acid and the like.

Other sources of hydrogen ions include carboxy polyesters prepared by the reaction of an excess of polycarboxylic acid or an anhydride thereof and a polyhydric alcohol to provide pendant carboxyl groups.

Still other materials capable of providing hydrogen ions are ion exchange resins having exchangeable hydrogen ions attached to base resins comprising cross-linked resinous polymers of monovinyl aromatic monomers and polyvinyl compounds. These resins are Well known materials which are generally prepared by copolymerizing in the presence of a polymerization catalyst one or more monovinyl aromatic compounds, such as styrene, vinyl toluene, vinyl xylene, with one or more divinyl aromatic compounds such as divinyl benzene, divinyl toluene, divinyl xylene, divinyl naphthalene and divinyl acetylene. Following copolymerization, the resins are sulfonated to provide the hydrogen form of the resin.

Still another class of compounds which can be employed are ammonium compounds which decompose to provide hydrogen ions when an aluminosilicate treated with a solution of said ammonium compound is subjected to temperatures below the decomposition temperature of the aluminosilicate.

Representative ammonium compounds which can be employed include ammonium hydroxide, ammonium chloride, ammonium bromide, ammonium iodide, ammonium carbonate, ammonium bicarbonate, ammonium sulfate, ammonium sulfide, ammonium thiocyanate, ammonium dithiocarbamate, ammonium peroxysulfate, ammonium acetate, ammonium tungstate, ammonium molybdate, ammonium benzoate, ammonium borate, ammonium carbamate, ammonium sesquicarbonate, ammonium chloroplumbate, ammonium citrate, ammonium dithionate, ammonium fluoride, ammonium gallate, ammonium nitrate, ammonium nitrite, ammonium formate, ammonium propionate, ammonium butyrate, ammonium valerate, ammonium lactate, ammonium malonate, ammonium oxalate, ammonium palmitate, ammonium tartrate and the like. Still other ammonium compounds which can be employed include complex ammonium compounds such as tetramethylammonium hydroxide, trimethylammonium chloride. Other compounds which can be employed are nitrogen bases such as the salts of guanidine, pyridine, quinoline, etc.

A wide variety of metallic compounds can be employed with facility as a source of metallic cations and include both inorganic and organic salts of the metals of Groups I through VIII of the Periodic Table.

Representative of the salts which can be employed include chlorides, bromides, iodides, carbonates, bicarbonates, sulfates, sulfides, thiocyanates, dithiocarbamates, peroxysulfates, acetates, benzoates, citrates, fluorides, nitrates, nitrites, formates, propionates, butyrates, valerates, lactates, malonates, oxalates, palmitates, hydroxides, tartrates and the like. The only limitation on the particular metal salt or salts employed is-that it be soluble in the fluid medium in which it is used. The preferred salts are the chlorides, nitrates, acetates and sulfates.

Rare earth salts may be advantageously employed. Such salts can either be the salt of a single metal or, preferably, of mixtures of metals such as a rare earth chloride or didymium chlorides. As hereinafter referred to, a rare earth chloride solution is a mixture of rare earth chlorides consisting essentially of the chlorides of lanthanum, cerium, neodymium and praseodymium with minor amounts of samarium, gadolinium and yttrium. The rare earth chloride solution is commercially available and it contains the chlorides of a rare earth mixture having the relative composition: cerium v(as CeO 48% by weight; lanthanum (as La O 24% by Weight; praseodymium (as Pr O 5% by weight; neodymium (as Nd O 17% by weight; samarium (as $111 3% by weight; gadolinium (as 0e 0,) 2% by weight; yttrium (as Y O 0.2% by weight; and other rare earth oxides 0.8% by weight. Didymium chloride is also a mixture of rare earth chlorides, but having a low cerium content. It consists of the following rare earths determined as oxides; lanthanum, 45-46% by weight; cerium, l2% by weight; praseodymium, 910% by weight; neodymium, 32-33% by weight; samarium, 6% by weight; gadolinium, 3-4% by weight; yttrium, 0.4% by weight; other rare earths, 12% by weight. It is to be understood that other mixtures of rare earths are equally applicable in the instant invention.

Representative metal salts which can be employed, aside from the mixture mentioned above, include silver nitrate, silver acetate, silver arsenate, silver citrate, silver oxide, silver tartrate, calcium acetate, calcium arsenate, calcium benzoate, calcium bromide, calcium carbonate, calcium chloride, calcium citrate, beryllium bromide, beryllium carbonate, beryllium hydroxide, beryllium sulfate, barium acetate, barium bromide, barium carbonate, barium citrate, barium malonate, barium nitrite, barium oxide, barium sulfide, magnesium chloride, magnesium bromide, magnesium sulfate, magnesium sulfide, magnesium acetate, magnesium formate, magnesium stearate, magnesium tartrate, manganese chloride, manganese sulfate, manganese acetate, manganese carbonate, manganese for-mate, zinc sulfate, zinc nitrate, zinc acetate, zinc chloride, zinc bromide, aluminum chloride, aluminum bromide, aluminum acetate, aluminum citrate, aluminum nitrate, aluminum oxide, aluminum phosphate, aluminum sulfate, titanium bromide, titanium chloride, titanium nitrate, titanium sulfate, zirconium chloride, zirconium nitrate, zirconium sulfate, chromic acetate, chromic chloride, chromic nitrate, chromic sulfate, ferric chloride, ferric bromide, ferric acetate, ferrous chloride, ferrous arsenate, ferrous lactate, ferrous sulfate, nickel chloride, nickel bromide, cerous acetate, cerous bromide, cerous carbonate, cerous chloride, cerous iodide, cerous sulfate, cerous sultide, lanthanum chloride, lanthanum bromide, lanthanum nitrate, lanthanum sulfate, lanthanum sulfide, yttrium bromate, yttrium bromide, yttrium chloride, yttrium nitrate, yttrium sulfate, samarium acetate, samarium chloride, samarium bromide, samarium sulfate, neodymium chloride, neodymium oxide, neodymium sulfide, neodymium sulfate, praseodymium chloride, praseodymium bromide, praseodymium sulfate, praseodymium sulfide, selenium chloride, selenium bromide, tellurium chloride, tellurium bromide, etc.

The aluminosilicate catalysts useable in connection with the process of the present invention may be used in powdered, granular or molded state formed into spheres or pellets of finely divided particles having a particle size of 2 to 500 mesh. In cases where the catalyst is molded, such as by extrusion, the aluminosilicate may be extruded before drying, or dried or partially dried and then extruded. The catalyst product is then preferably precalcined in an inert atmosphere near the temperature contemplated for conversion but may be calcined initially during use in the conversion process. Generally, the aluminosilicate is dried between 150 F. and 600 F. and thereafter calcined in air or an inert atmosphere of nitrogen, hydrogen, helium, flue gas or other inert gas at temperatures ranging from about 500 F. to 1500 F. for periods of time ranging from 1 to 48 hours or more.

The aluminosilicate catalyst prepared in the foregoing manner may be used as catalysts per se or as intermediates in the preparation of further modified contact masses consisting of inert and/ or catalytically active materials which otherwise' serve as a base, support, carrier, binder, matrix or promoter for the aluminosilicate. One embodiment of the invention is the use of the finely divided aluminosilicate catalyst particles in a siliceous gel matrix wherein the catalyst is present in such proportions that the resulting product contains about 2 to by weight, preferably about 5 to 75% by weight, of the aluminosilicate in the final composite.

The aluminosilicate-siliceous gel compositions can be prepared by several methods wherein the aluminosilicate is combined with silica while the latter is in a hydrous state such as in the form of a hydrosol, hydrogel, wet gelatinous precipitate or a mixture thereof. Thus, silica gel formed by hydrolyzing a basic solution of alkali metal silicate with an acid such as hydrochloric, sulfuric, etc., can be mixed directly with finely divided aluminosilicate having a particle size less than 40 microns, preferably Within the range of 2 to 7 microns. The mixing of the two components can be accomplished in any desired manner, such as in a ball mill or other types of kneading mills. Similarly, the aluminosilicate may be dispersed in a hydrosol obtained by reacting an alkali metal silicate with an acid or an alkaline coagulent. The hydrosol is then permitted to set in mass to a hydrogel which is thereafter dried and broken into pieces of desired shape, or dispersed through a nozzle into a bath of oil or other Water-immiscible suspending medium to obtain spheroidally shaped bead particles of catalyst. The aluminosilicate siliceous gel thus obtained is washed free of soluble salts and thereafter dried and/or calcined as desired.

The siliceous gel matrix may also consist of a plural gel comprising a predominant amount of silica with one or more metals or oxides thereof. The preparation of plural gels is well known and generally involves either separate precipitation or coprecipitation techniques in which a suitable salt of the metal oxide is added to an alkali metal silicate and an acid or base, as required, is added to precipitate the corresponding oxides. The silica content of the siliceous gel matrix contemplated herein is generally with the range of 55 to weight percent with the metal oxide content ranging from zero to 45 percent. Minor amounts of promoters or other materials which may be present in the composition include cerium, chromium, cobalt, tungsten, uranium,

platinum, lead, zinc, calcium, magnesium, lithium, silver, nickel and their compounds.

The aluminosilicate catalyst may also be incorporated in an alumina gel matrix conveniently prepared by adding ammonium hydroxide, ammonium carbonate, etc. to a salt of aluminum, such as aluminum chloride, aluminum sulfate, aluminum nitrate, etc., in an amount to 13 form aluminum hydroxide, which, upon drying, is converted to alumina. The aluminosilicate catalyst can be mixed with the dried alumina or combined while the alumina is in the form of a hydrosol, hydrogel or wet gelatinous precipitate.

The preferred crystalline aluminosilicates usable as the catalyst in the carbonylation reactions of the present invention are those having a minimum activity of at least about 10 in the hexane cracking test. The hexane cracking test may be described as follows:

The catalyst to be evaluated for cracking activity is placed in a reactor into which n-hexane is fed. The flow rate of the n-hexane, catalyst sample size and temperature in the reactor are preselected to obtain conversion levels in the range of to 50 weight percent. The hexane is fed to the reactor until the catalyst to oil ratio (volume basis) equals about 4. At this time a sample of the reaction products is taken and analyzed by gas chromatography.

The conversion of n-hexane determined from the chromatograph is converted to a reaction rate constant by the assumption of a first order or pseudo-first order reaction. Some trial and error may be necessary to select particular conditions. As a general guide, space velocity and temperature can be varied until a conversion is in the above range. If it should happen that the catalyst has a heavy coke deposit at low conversion severity should be decreased. The value obtained is normalized by dividing by the reaction rate constant for a conventional silica-alumina catalyst containing about weight percent alumina and a CAT-A activity of 46 as described in National Petroleum News 36, page P.R.-537 (Aug. 2, 1944). Such catalyst is hereinafter designated as 46AI silica-alumina catalyst. This value is then corrected to 1000 F. by the use of an Arrhenius plot if the evaluation occurred at some other temperature. Results are therefore reported as relative reaction rate constants at 1000" F.

The range of operating conditions for this test are as follows:

Temperature in reactor 700 to 1000 F. Liquid hourly space velocity 0.2 to 60. n-Hexane flow rate 2 to 30 cc./ hr. Catalyst volume in reactor 0.5 to 10 cc.

The test conditions are usually chosen so that time on stream is between seconds and 30 minutes and preferably between 30 seconds and 15 minutes. When used in this specification and/or claims, the term minimum activity will be understood to be the constant obtained for the catalyst in question in accordance with the above test.

Consistent with the above considerations, preferred catalysts in the reactions of the present invention are those which have come to be known as the superactive H-zeolities, including, for example, acid mordenite, acid en'onite and acid chabazite. Also particularly advantageous in the process of the present invention are the rare earth-exchanged crystal-line aluminosilicates and those containing a metal which will form a carbonyl complex. Preferred metals in the latter category include iron, nickel and cobalt. Preferred pore sizes in the catalyst are from The reactions of the present invention may be carried out at temperatures of about 50-750 F., with temperatures of 200400 F. being preferred. While higher pressures (viz, above about 1000 p.s.i.g.) are desirable, an overall range of pressures is 5010,000 p.s.i.g.

The process of the present invention may be carried out either on a batch basis or in a continuous manner. Batch treatment of the charge stock may be effected in reactors or autoclaves of suitable design in which the charge and catalyst are exposed to the desired conditions of operation for a time sufficient to effect the desired results. Under such conditions of operation, the molecular sieve catalyst should be present in a quantity of approximately 510% by weight of the mixture of catalyst and charge stock.

The process of the present invention may be carried out on a continuous basis in a reactor containing a fixed bed or layer of the molecular sieve catalyst through which the charge stock is passed under the desired conditions of temperature and pressure. Under such conditions of operation, the reaction products are discharged continuously from the reactor at substantially the same rate as that under which the charge stock is fed into the reactor. If desired, of course, a continuous process utilizing a fluidized bed may be employed in a conventional manner.

In carrying out the process of the present invention under continuous reaction conditions, in which the charge stock is passed continuously through a bed of the catalyst, an acceptable liquid hourly space velocity of about 0.1- 10 vol. of charge stock/vol. cat/hr. and a gaseous space velocity of about 10100 may be utilized. The carbon monoxide should be present in a slight excess (over equimolar quantities) with respect to the quantity of organic charge stock to be carbonylated through CO: charge stock molar ratios may be up to about 10:1. When hydrogen is used to promote the reaction, the hydrogen may be present in the feed gas in an approximately 1:1 molar ratio with respect to the CO.

Following are examples illustrating the practice of the present invention:

EXAMPLES 1-8 Carbonylation of olefins to give unsaturated aldehydes Examples 16 all involve acid (hydrogen-exchanged) mordenite catalysts. Some reaction occurred at 70 F. (Ex. 1), but not as much as at 250 F. (Ex. 2). At 400 F. (Ex. 3), polymerization was more rapid than at 250 F., its rate having increased more than that of the carbonylation reaction. Higher pressures of over 1000 p.s.i. g. are desirable for the carbonylation reaction (Ex. 2, calculated 1740 p.s.i.g. at 250 F., vs. EX. 4, calculated 670 p.s.i.g. at 250 F.). Carbon monoxide alone (Ex. 5 without hydrogen did not give as much carbonylation product. In the absence of CO but with an equivalent nitrogen pressure (Ex. 6), propylene polymer yield increased five fold. Thus, CO and/ or the product aldehyde inhibit polymerization of the olefin, which is undesirable.

Examples 7 and 8 utilize catalysts other than acid mordenite. Carbonylation occurred over cobalt mordenite (Ex. 7) and REHX (rare earth and hydrogen-exchanged X-type molecular sieve) (Ex. 8) catalysts.

In Examples 18, the experimental procedure involved preparation of the catalyst in powdered form (greater than 200 mesh), calcining the powder at 1000 F., charging the powder to the autoclave and evacuating the autoclave at 2 mm. pressure while heating to 900 F. The autoclave was then cooled to room temperature, then in Dry Ice, and the propylene charged. The autoclave was then warmed to room temperature and full tank pressure of the carbonylation gas charged. The valve at the head of the autoclave was closed during the reaction period to avoid plugging the line with catalyst powder. The autoclave was then heated to the reaction temperature and held at this temperature with rocking for the indicated period of time. At the end of the reaction period, the autoclave (at 250 F.) was vented into a Dry Ice trap and the trap was weathered to room temperature. The residual liquid was weighed and reported as liquid product.

TABLE I.-PROPYLENE CARBONYLATION' [1 Liter Rocking Autoclave Example No.

Catalyst i Cobalt 7 Acid Mordenite Mordenite REIlX 50 50 50 50 50 50 150 Propylene, g 60 61 61 62 60 74 .1 60 Mles .5 1.4 1.4 1.4 1.5 1.6 1.8 1.4 Carbonylation gas C 0/112 (JO/H2 C OiH; 00 None 0 O/Hz (BO/H2 7 Pressure at room temp, p. i 1,780 1,300 1, 150 500 1,300 1,300(Nz) 1,425 1,300 Grams, approx 47 34 30 13 64 34 g 34 Moles, approx- 3. 1 2. 3 2. 0 0. 9 2. 3 2. 3 2.3 Temp, 70 250 400 250 250 250 250 250 Time, hours 168 23 23% 23 23% 24 21 23% Liquid product:

Yield, 0. 8. 3 23.1 2. 2 5. 3 3-3. 7 9. 1 4. 1 Oxygen'content, wt. percent. 0. 93 4. 05 0. 74 0. 41 2. 53 0. 38 1. 78 Max. 04 aldehyde, Wtfl- 4 18 3 2 11 i 3 Carbonyl oxygen, IR Strong Trace Trace Present Present Present Test for Carbonyl with 2 phenyl hydrazine Positive Negative Positive Negative Positive Polymer, wt. percent of propylene char e 1 11 37 4 8 53 12 7 Ono. distribution:

1 5.44 Wt. percent C00.

2 Identified by gas chromatography as methactoloin. This aldehyde is not stable upon exposure to light and air, solids precipitating and adol condensation being indicated. B Analyzed by gas chromatography.

EXAMPLES 9 AND Carbonylation of unsaturated halides Example 9: Acid mordenite, allyl chloride, CO/l-I Fifty grams of acid mordenite catalyst, '76 g. (1 mole) of allyl chloride, and approximately 24 g. CO/H (0.8 mole each, 900 p.s.i.g. pressure at room temperature) were reactcd together at 250 F. for 24 hours. Unreacted allyl chloride was distilled out at 250 F. and the catalyst extracted with petroleum ether. The 0.5 g. of extract contained 9 wt. percent oxygen and showed a carbonyl absorption of 5 .8 (infrared analysis).

Example 10: Acid mordenite, allyl bromide, CO/H Fifty grams of acid mordenite catalyst, 119 g. (1 mole) of allyl bromide and approximately 46 g. CO/H (1.5 moles each, 1770 p.s.i.g. pressure at room temperature) were reacted together at 250 F. for 19 hours. Unrcacted allyl bromide was distilled out at 250 F. and the catalyst extracted With petroleum ether. The 2.9 g. of extract containcd 3.12 wt. percent oxygen and showed a carbonyl absorption at 5.8 (infrared analysis).

In the foregoing portion of the specification, a novel process for carbonylating specified organic compounds in the presence of crystalline aluminosilicate catalysts has been set forth. It is to be understood, however, that the process of the present invention is also applicable to the use in said carbonylation process of isomorphs of said crystalline aluminosilicatcs. For example, the aluminum may be replaced by elements such as gallium and silicon by elements such as gallium and silicon by elements such as germanium.

The invention may be embodied in other specific forms Without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

What is claimed:

1. A process for carbonylating an olcfinic hydrocarbon selected from ethylene, propylene, l-butcnc, 1-pcntene, 1- hexcne, l-hcptcne, l-octene, l-decene, l-tctradcccne, 2- pcntcnc, Z-hcxcnc, Z-heptenc, 3-heptene, 2-octene, 4- methyl-1-pcntene, Z-methyl-l-pentcnc, 2,4,4-trimcthyl-1- pcntcnc, 2,3,3-trimethyl-l-butcne, camphene, 4-methyl-2- pcntene, 2-mcthyl-2-pentene, 2,4,4trimcthyl-2-pentcne, 2,3-dimethyl-2-butcne, 2,6-dimethyl-3-hcptene, cyclopen tone, cyclohexcne, cycloheptcne, cyclooctenc, and 4- methyl-l-cyclohexcne, comprising reacting said hydrocarbon with CO in the presence of hydrogen and a dehydrated solid, porous crystalline aluminosilicatc catalyst having internal pores of about 3-16 A. at a temperature of about ZOO-400 F. and a pressure of at least about 1,000 p.s.i.g. the ratio of CO to hydrocarbon being from an amount slightly in excess of a 1:1 molar ratio to about a 10:1 molar ratio, said crystalline aluminosilicate being selected from the group consisting of acid mordenitc and rare earth acid Zcolitc X.

2. A process for producing mcthacrolein comprising carbonylating propylene with CO in the presence of hydrogcn and a dehydrated solid, porous crystalline aluminosilicate catalyst having internal pores of about 3-16 A. at a temperature of about ZOO-400 F. and a pressure of at least about 1,000 p.s.i.g., the ratio of CO to propylene being from an amount slightly in excess of a 1:1 molar ratia to about a 10:1 molar ratio, said crystalline aluminosilicate being selected from the group consisting of acid mordcnitc and rare earth acid Zeolitc X.

References Cited 7 I STATES PATENTS 1% UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 9, Dated January 13, 1970 Inventor) WILLIAM E. GARWOOD and LYLE A. HAMILTON It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line l t, "carbonylatng should be --carbonylating-- Column 16, between lines 6-7, "Cobalt Mordenite" should be --Cobalt (l) Mordenite--. Column 15, lines 62-63, "by elements such as gallium and silicon by elements such as germanium should be --by elements such as germanium--.

SIGNED AND SEALED JU L 2 8 B mun r. sasum, an. Edward M. Fletcher, In nions:- of Patents Aneating Officer 

